Bonding method of semiconductor chip and bonding apparatus of semiconductor chip
Summary by NHIP
Chip bonding with elastic sheet
The apparatus arranges a chip and substrate with their activated front surfaces facing each other while the chip back surface attaches to an elastic sheet. A holding mechanism secures the sheet periphery while a pushing head deforms the sheet portion under the chip to bond surfaces, then strips the sheet by retracting a pin and releasing push force.
Claim Score by NHIP
Abstract
According to one embodiment, there is provided a bonding method of a semiconductor chip. The bonding method includes arranging an activated front surface of a semiconductor chip and an activated front surface of a substrate so as to face each other with a back surface of the semiconductor chip attached to a sheet. The bonding method includes pushing the back surface of the semiconductor chip through the sheet to closely attach the activated front surface of the semiconductor chip and the activated front surface of the substrate. The bonding method includes stripping the sheet from the back surface of the semiconductor chip while maintaining a state in which the activated front surface of the semiconductor chip is closely attached to the activated front surface of the substrate.

Term
8.6 yearsleft in the term
Expires 12 May 2035.
- Priority
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18 claims: 3 independent, 15 dependent
- 1A mounting apparatus for a chip comprising:an arrangement mechanism configured to arrange a front surface of the chip and a front surface of a substrate so as to face each other in a state where a back surface of the chip is attached to a sheet with elasticity, the sheet having a first portion and a second portion, the first portion corresponding to the chip, and the second portion being arranged at a periphery of the first portion in the sheet when seen in a direction perpendicular to the front surface of the substrate;a holding mechanism capable of moving in a direction that is not perpendicular to the front surface of the substrate so as to be arranged to hold the second portion of the sheet;and a pushing mechanism configured to push the back surface of the chip through the first portion of the sheet to attach the front surface of the chip to the front surface of the substrate with the first portion elastically deformed in a state where the second portion is held by the holding mechanism, and configured to strip the sheet from the back surface of the chip while maintaining a state in which the front surface of the chip is attached to the front surface of the substrate, by releasing the pushing force to mechanism from the first portion of the sheet.
- 10A mounting apparatus for a chip comprising:an arrangement mechanism configured to arrange a front surface of a chip and a front surface of a substrate so as to face each other in a state where a back surface of the chip is attached to a sheet with elasticity, the sheet having a first portion and a second portion, the first portion corresponding to the chip, and the second portion being arranged at a periphery of the first portion in the sheet when seen in a direction perpendicular to the front surface of the substrate;a holding mechanism capable of moving in a direction that is not perpendicular to the front surface of the substrate so as to be arranged to hold the second portion of the sheet;and a pushing mechanism configured to push the back surface of the chip through the first portion of the sheet to attach the front surface of the chip to the front surface of the substrate with the first portion elastically deformed in a state where the second portion is held by the holding mechanism, and configured to strip the sheet from the back surface of the chip, by releasing the pushing force to mechanism from the first portion of the sheet, wherein the pushing mechanism includes: a pushing head including a pushing surface corresponding to the back surface of the chip;and a pin configured to retract from the pushing surface and to project from the pushing surface.
- 14Broadest claimClaim Score 58, broad(NHIP)A mounting apparatus comprising:an arrangement mechanism configured to arrange front surfaces of a plurality of chips and a front surface of a substrate so as to face each other in a state where back surfaces of the chips are attached to a sheet with elasticity, the sheet having a first portion and a second portion, the first portion corresponding to a selected one of the chips, and the second portion being arranged at a periphery of the first portion in the sheet when seen in a direction perpendicular to the front surface of the substrate;a holding mechanism capable of moving in a direction that is not perpendicular to the front surface of the substrate so as to be arranged to hold the second portion of the sheet;and a pushing mechanism configured to push the back surface of the selected one of the chips through the first portion of the sheet to attach the front surface of the one of the chips to the front surface of the substrate with the first portion elastically deformed in a state where the second portion is held by the holding mechanism, and configured to strip the sheet from the back surface of the one of the chips, by releasing the pushing force to mechanism from the first portion of the sheet.
Independent claims3
188 paragraphs in 5 sections, as filed
CROSS-REFERENCE TO RELATED APPLICATIONS
0001This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2014-221907, filed on Oct. 30, 2014; the entire contents of which are incorporated herein by reference.
FIELD
0002Embodiments described herein relate generally to a bonding method of a semiconductor chip and a bonding apparatus of the semiconductor chip.
BACKGROUND
0003A semiconductor chip is mounted and bonded on a substrate to obtain a semiconductor device. In this case, the semiconductor chip is desirably mounted on the substrate while suppressing thermal deformation of the semiconductor chip and suppressing position shift in the bonding that occurs from the difference in the coefficients of thermal expansion of the semiconductor chip and the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
0004<figref idref="DRAWINGS">FIGS. 1A to 1G</figref> are cross-sectional views illustrating a bonding method of a semiconductor chip according to an embodiment;
0005<figref idref="DRAWINGS">FIG. 2A</figref> is a cross-sectional view illustrating a configuration of a bonding apparatus of the semiconductor chip according to the embodiment;
0006<figref idref="DRAWINGS">FIG. 2B</figref> is a bottom view of a pushing head in the bonding apparatus according to the embodiment;
0007<figref idref="DRAWINGS">FIGS. 3A to 3C</figref> are cross-sectional views illustrating a bonding method of the semiconductor chip according to the embodiment;
0008<figref idref="DRAWINGS">FIGS. 4A to 4C</figref> are cross-sectional views illustrating the bonding method of the semiconductor chip according to the embodiment;
0009<figref idref="DRAWINGS">FIGS. 5A to 5D</figref> are cross-sectional views illustrating the bonding method of the semiconductor chip according to the embodiment;
0010<figref idref="DRAWINGS">FIGS. 6A to 6D</figref> are explanatory views illustrating a mechanism of plasma activated bonding according to the embodiment; and
0011<figref idref="DRAWINGS">FIGS. 7A to 7D</figref> are cross-sectional views illustrating a bonding method of a semiconductor chip according to a variant of the embodiment.
DETAILED DESCRIPTION
0012In general, according to one embodiment, there is provided a bonding method of a semiconductor chip. The bonding method includes arranging an activated front surface of a semiconductor chip and an activated front surface of a substrate so as to face each other with a back surface of the semiconductor chip attached to a sheet. The bonding method includes pushing the back surface of the semiconductor chip through the sheet to closely attach the activated front surface of the semiconductor chip and the activated front surface of the substrate. The bonding method includes stripping the sheet from the back surface of the semiconductor chip while maintaining the state in which the activated front surface of the semiconductor chip is closely attached to the activated front surface of the substrate.
0013Exemplary embodiments of a bonding method of a semiconductor chip will be explained below in detail with reference to the accompanying drawings. The present invention is not limited to the following embodiments.
Embodiment
0014A bonding method of a semiconductor chip according to an embodiment will be described. The bonding method of the semiconductor chip is a method for mounting a semiconductor chip on a substrate.
0015For example, a plurality of chips needs to be stacked in a packaging step of a device to obtain a stacked type device. In this case, if chips of different chip sizes coexist in a plurality of chips to be stacked, it is difficult to first bond two substrates and then collectively singulate the substrates to obtain the stacked type device. Thus, one substrate (semiconductor substrate) of the two substrates first needs to be singulated to a plurality of semiconductor chips, and then the semiconductor chips need to be mounted on the other substrate.
0016Alternatively, an optical element needs to be stacked on a template substrate to obtain an optical device. In this case, if substrate sizes of a substrate for the optical element to be singulated to a plurality of optical elements and a substrate for the template substrate to be singulated to a plurality of template substrates are different, a useless region that does not contribute to obtaining the optical device forms when the two substrates are bonded. Thus, one substrate (semiconductor substrate) for the optical element of the two substrates needs to be first singulated to a plurality of semiconductor chips, and then the chips need to be mounted on the other substrate.
0017Consider a case of interposing a solder bump between a pad electrode of the semiconductor chip and a pad electrode of the substrate for conduction.
0018In this case, the semiconductor chip and the substrate need to be heated to a high temperature (e.g., 350 to 400° C.) to solder bond the solder bump to each of the pad electrode of the semiconductor chip and the pad electrode of the substrate, and hence there is a possibility the semiconductor chip and the substrate may thermally deform. If the semiconductor chip and the substrate are made from materials of different coefficients of thermal expansion, the alignment accuracy in the bonding of the pad electrode of the semiconductor chip and the pad electrode of the substrate may lower and the electrodes may not be conducted if the semiconductor chip and the substrate are thermally deformed.
0019In the present embodiment, as illustrated in <figref idref="DRAWINGS">FIG. 1</figref> to <figref idref="DRAWINGS">FIG. 5</figref>, the semiconductor chip is mounted at a normal temperature on the substrate by plasma activated bonding of the semiconductor chip to the substrate. In other words, the semiconductor chip is temporarily bonded at a normal temperature on the substrate by activating the front surface of the semiconductor chip and the front surface of the substrate by plasma and closely attaching the semiconductor chip to the substrate. Thereafter, the semiconductor chip is heated and pressurized to be actually bonded to the substrate. The bonding position of the semiconductor chip on the substrate can be substantially fixed with the temporary bonding, and hence the alignment accuracy in the bonding of the semiconductor chip can be easily enhanced in the actual bonding.
0020It should be noted that, if electrical conduction is required between the semiconductor chip and the substrate as in the bonding of the semiconductor chip and the substrate using the solder bump described above, a conductor electrode may be arranged on a part of the respective front surface of the semiconductor chip and the substrate to be activated, and the conductors may be electrically connected apart from the bonding by the plasma activation. For example, a solder electrode surrounded by an insulating film (silicon dioxide film) is prepared on the front surface in each of the semiconductor chip and the substrate. The insulating films in each of the semiconductor chip and the substrate may be bonded and then heated to melt the solder electrodes thus bonding the solder electrodes.
0021<figref idref="DRAWINGS">FIGS. 1A to 1G</figref>, <figref idref="DRAWINGS">FIGS. 3A to 3C</figref>, and <figref idref="DRAWINGS">FIGS. 4A to 4C</figref> are step cross-sectional views illustrating a bonding method of the semiconductor chip. <figref idref="DRAWINGS">FIG. 2A</figref> is a cross-sectional view illustrating a configuration of a bonding apparatus of the semiconductor chip. <figref idref="DRAWINGS">FIG. 2B</figref> is a bottom view of a pushing head in the bonding apparatus.
0022It should be noted that, the activation in the plasma activated bonding refers to terminating the front surface of the semiconductor chip and the front surface of the substrate with a hydroxyl group to realize a state in which water molecules can be easily bonded. The plasma activated bonding is also sometimes referred to as oxide bonding, fusion bonding, spontaneous bonding, or the like.
0023In the bonding method of the semiconductor chip, the steps illustrated in <figref idref="DRAWINGS">FIGS. 1A to 1D</figref> and the steps illustrated in <figref idref="DRAWINGS">FIGS. 1E to 1G</figref> are carried out in parallel as a pre-process of the temporary bonding in the plasma activated bonding.
0024In the step illustrated in <figref idref="DRAWINGS">FIG. 1A</figref>, a semiconductor substrate <b>10</b> to be singulated to a plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> (see <figref idref="DRAWINGS">FIG. 1B</figref>) is prepared. A portion (excluding a pad electrode) in the vicinity of a front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> is made of a material having any one of silicon, silicon oxide, III-V group semiconductor, and an oxide of the III-V group semiconductor as a main component. If the portion in the vicinity of the front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> is made of a material having the silicon oxide as the main component, a region deeper than the portion in the vicinity of the front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> may be made of a material having the silicon as the main component or a material having the III-V group semiconductor as the main component. If the portion in the vicinity of the front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> is made of a material having the oxide of the III-V group semiconductor as the main component, the region deeper than the portion in the vicinity of the front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> may be made of a material having the III-V group semiconductor as the main component. The III-V group semiconductor includes, for example, InP, GaAs, and GaN.
0025The front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> can have planarity of smaller than or equal to 1 nm, and more preferably, smaller than or equal to 0.3 nm. If the planarity of the front surface <b>10</b><i>a </i>is smaller than or equal to 0.3 nm, the planarity of a front surface <b>11</b><i>a </i>of each singulated semiconductor chip <b>11</b> also becomes smaller than or equal to 0.3 nm. If the planarity of the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> is smaller than or equal to 0.3 nm, a void (air gap) forms at a bonding interface when the semiconductor chip <b>11</b> is temporarily bonded to the substrate <b>20</b> in the step (step illustrated in <figref idref="DRAWINGS">FIG. 5D</figref>) of the actual bonding, and the bonding strength of the actual bonding can be suppressed from not meeting the required strength.
0026For example, the planarity of the front surface <b>10</b><i>a </i>can be made to smaller than or equal to 1 nm or can be made to smaller than or equal to 0.3 nm by polishing the front surface <b>10</b><i>a </i>of the semiconductor substrate <b>10</b> through the CMP method, and the like.
0027Next, a back surface <b>10</b><i>b </i>of the prepared semiconductor substrate <b>10</b> is attached to a front surface <b>1</b><i>a </i>of an adhesive sheet (dicing tape) <b>1</b>. In other words, the semiconductor substrate <b>10</b> is attached to the adhesive sheet <b>1</b> with the front surface <b>10</b><i>a </i>exposed (face-up state). The adhesive sheet <b>1</b> has an adhesive applied on the front surface <b>1</b><i>a</i>. The adhesive may be an adhesive having UV curability, for example. The adhesive sheet <b>1</b> is stretched within a frame of an annular flat ring <b>2</b> and fixed to the flat ring <b>2</b>. The adhesive sheet <b>1</b> is formed, for example, with a transparent resin having light permeability.
0028In the step illustrated in <figref idref="DRAWINGS">FIG. 1B</figref>, the semiconductor substrate <b>10</b> is divided to be singulated into the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b>. For example, the semiconductor substrate <b>10</b> is dicing processed along a dicing line. The dicing processing may be carried out by cutting with a dicing blade along the dicing line. In this case, the cutting may be carried out with the dicing blade while introducing water jet, formed by thinly injecting water, to a cutting area. Cutting scraps (particles) thus can be prevented from attaching to the front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b>. Alternatively, the dicing processing may be carried out by emitting a laser along the dicing line and performing laser processing.
0029Thereafter, UV irradiation may be carried out on the adhesive sheet <b>1</b> from the back surface <b>1</b><i>b </i>side to cure the adhesive applied on the front surface <b>1</b><i>a </i>of the adhesive sheet <b>1</b>, thus lowering the adhesion force thereof.
0030Furthermore, washing (e.g., ultrasonic washing) and drying processes are sequentially carried out on the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> with each semiconductor chip <b>11</b> attached to the adhesive sheet <b>1</b>. If the particles are attached to the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b>, the attached particles thus can be removed.
0031In the step illustrated in <figref idref="DRAWINGS">FIG. 1C</figref>, an interval of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> on the adhesive sheet <b>1</b> is widened.
0032For example, the adhesive sheet <b>1</b> is once detached from the flat ring <b>2</b>, and then the adhesive sheet <b>1</b> is pulled to spread toward the periphery with the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> attached thereto. The interval of the adjacent semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> thus can be widened.
0033At this time, as illustrated in <figref idref="DRAWINGS">FIG. 1C</figref>, the interval of the adjacent semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> can be widened to greater than the thickness of each semiconductor chip <b>11</b>. If the interval of the adjacent semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> is smaller than or equal to the thickness of each semiconductor chip <b>11</b>, a side surface <b>11</b><i>c </i>of the semiconductor chip <b>11</b> to be pushed makes contact with a side surface <b>11</b><i>c </i>of the adjacent semiconductor chip <b>11</b> and may possibly produce particles in the step (step illustrated in <figref idref="DRAWINGS">FIG. 5A</figref>) of pushing the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>. If the produced particles are attached to the surface to be temporarily bonded, a void (air gap) having the particle as the starting point forms at the bonding interface when the semiconductor chip <b>11</b> is temporarily bonded to the substrate <b>20</b>, and the bonding strength of the temporary bonding may not meet the required strength. For example, if a particle having a diameter of 1 μm is interposed at the bonding surface, there is a possibility a void having a width in the direction along the bonding interface of about 1000 μm may form.
0034In the step illustrated in <figref idref="DRAWINGS">FIG. 1D</figref>, the front surfaces <b>11</b><i>a </i>of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> are collectively activated. For example, the flat ring <b>2</b>, to which the adhesive sheet <b>1</b> attached with the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> are fixed, is mounted on a stage in a processing chamber of a plasma processing device (not illustrated). In this case, the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> is facing the upper side. When plasma PL<b>1</b> is irradiated onto the front surfaces <b>11</b><i>a </i>of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> under depressurization, the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> is activated. Thereafter, the flat ring <b>2</b>, to which the adhesive sheet <b>1</b> attached with the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> are fixed, is conveyed out to the exterior of the processing chamber.
0035Contaminated objects such as organic substances, and the like attached to the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> thus can be removed, and the front surface <b>11</b><i>a </i>can be terminated with the hydroxyl group. For example, a portion (excluding the pad electrode) in the vicinity of the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> is made from a material having any one of the silicon, the silicon oxide, the III-V group semiconductor, and the oxide of III-V group semiconductor as the main component. In any case, the front surface <b>11</b><i>a </i>can be activated and the front surface <b>11</b><i>a </i>can be terminated with the hydroxyl group according to the step illustrated in <figref idref="DRAWINGS">FIG. 1C</figref>.
0036It should be noted that, the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> may be activated by irradiating the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> with an energy beam (bombardment) of atoms such as Ar, and the like or ions, instead of irradiating the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> with the plasma.
0037In the meantime, in the step illustrated in <figref idref="DRAWINGS">FIG. 1E</figref>, a substrate <b>20</b> on which the semiconductor chip <b>11</b> is to be mounted is prepared. The substrate <b>20</b>, for example, includes a semiconductor substrate or a glass substrate. If the substrate <b>20</b> is the semiconductor substrate, a portion (excluding the pad electrode) in the vicinity of a front surface <b>20</b><i>a </i>of the substrate <b>20</b> is made of a material having any one of the silicon, the silicon oxide, the III-V group semiconductor, and the oxide of the III-V group semiconductor as the main component. If the portion in the vicinity of the front surface <b>20</b><i>a </i>in the substrate <b>20</b> is made of a material having the silicon oxide as the main component, a region deeper than the portion in the vicinity of the front surface <b>20</b><i>a </i>in the substrate <b>20</b> may be made of a material having the silicon as the main component or a material having the III-V group semiconductor as the main component. If the portion in the vicinity of the front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> is made of a material having the oxide of the III-V group semiconductor as the main component, a region deeper than the portion in the vicinity of the front surface <b>10</b><i>a </i>in the semiconductor substrate <b>10</b> may be made of a material having the III-V group semiconductor as the main component. The III-V group semiconductor includes, for example, InP, GaAs, and GaN. If the substrate <b>20</b> is the glass substrate, a portion (excluding the pad electrode) in the vicinity of the front surface <b>20</b><i>a </i>in the substrate <b>20</b> is made of a material having the silicon oxide or a sapphire as the main component, for example.
0038The front surface <b>20</b><i>a </i>in the substrate <b>20</b> can have planarity of smaller than or equal to 1 nm, and more preferably, smaller than or equal to 0.3 nm. If the planarity of the front surface <b>20</b><i>a </i>is smaller than or equal to 0.3 n, a void (air gap) forms at a bonding interface when the semiconductor chip <b>11</b> is temporarily bonded to the substrate <b>20</b> in the step (step illustrated in <figref idref="DRAWINGS">FIG. 5D</figref>) of the actual bonding, and the bonding strength of the actual bonding can be suppressed from not meeting the required strength.
0039For example, the planarity of the front surface <b>20</b><i>a </i>of the substrate <b>20</b> can be made to smaller than or equal to 1 nm or can be made to smaller than or equal to 0.3 nm by polishing the front surface <b>20</b><i>a </i>of the substrate <b>20</b> through the CMP method, and the like.
0040Furthermore, the washing (e.g., ultrasonic washing) and drying processes are sequentially carried out on the front surface <b>20</b><i>a </i>of the prepared substrate <b>20</b>. If particles are attached to the front surface <b>20</b><i>a </i>of the substrate <b>20</b>, the attached particles thus can be removed.
0041In the step illustrated in <figref idref="DRAWINGS">FIG. 1F</figref>, the front surface <b>20</b><i>a </i>of the substrate <b>20</b> is activated. For example, the substrate <b>20</b> is mounted on a stage in a processing chamber of a plasma processing device (not illustrated) such that the front surface <b>20</b><i>a </i>is facing the upper side. When plasma PL<b>2</b> is irradiated onto the front surface <b>20</b><i>a </i>of the substrate <b>20</b> under depressurization, the front surface <b>20</b><i>a </i>of the substrate <b>20</b> is activated. Thereafter, the substrate <b>20</b> is conveyed out to the exterior of the processing chamber.
0042Contaminated objects such as organic substances, and the like attached to the front surface <b>20</b><i>a </i>of the substrate <b>20</b> thus can be removed, and the front surface <b>20</b><i>a </i>can be terminated with the hydroxyl group. The portion (excluding the pad electrode) in the vicinity of the front surface <b>20</b><i>a </i>of the substrate <b>20</b> is made of a material having any one of the silicon, the silicon oxide, the III-V group semiconductor, and the oxide of III-V group semiconductor as the main component. In any case, the front surface <b>20</b><i>a </i>can be activated and the front surface <b>20</b><i>a </i>can be terminated with the hydroxyl group according to the step illustrated in <figref idref="DRAWINGS">FIG. 1F</figref>.
0043Furthermore, the washing (e.g., ultrasonic washing) and drying processes are sequentially carried out on the front surface <b>20</b><i>a </i>of the substrate <b>20</b> in the step illustrated in <figref idref="DRAWINGS">FIG. 1G</figref>. If the particles are attached to the front surface <b>20</b><i>a </i>of the substrate <b>20</b>, the attached particles thus can be removed.
0044In the bonding method of the semiconductor chip, the temporary bonding in the plasma activated bonding is carried out.
0045When temporarily bonding the semiconductor chip <b>11</b> to the substrate <b>20</b>, assume a case of picking up each semiconductor chip <b>11</b> and detaching from the adhesive sheet <b>1</b>, and mounting each semiconductor chip <b>11</b> on the substrate <b>20</b>. In this case, a part of the semiconductor chip <b>11</b> may chip and produce particles when the front surface <b>11</b><i>a </i>or the side surface <b>11</b><i>c </i>of the semiconductor chip <b>11</b> is touched, and such produced particles may attach to the front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b>. If the produced particles are attached to the front surface <b>11</b><i>a</i>, a void (air gap) having the particle as the starting point may form at the bonding interface when the semiconductor chip <b>11</b> is temporarily bonded to the substrate <b>20</b>, and the bonding strength of the temporary bonding may not meet the required strength. For example, if the particle having a diameter of 1 μm is interposed at the bonding interface, there is a possibility a void having a width in the direction along the bonding interface of about 1000 μm may form.
0046In the present embodiment, a devisal is made to handle the semiconductor chip <b>11</b> without touching the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> when temporarily bonding the semiconductor chip <b>11</b> to the substrate <b>20</b>. In other words, the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> attached to the adhesive sheet <b>1</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> are arranged to face each other, and the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> is pushed through the adhesive sheet <b>1</b> to temporarily bond the semiconductor chip <b>11</b> to the substrate <b>20</b>, so that the temporary bonding is carried out while suppressing the production of particles.
0047Specifically, the temporary bonding of the plasma activated bonding is carried out using a bonding apparatus <b>100</b> illustrated in <figref idref="DRAWINGS">FIGS. 2A and 2B</figref>.
0048As illustrated in <figref idref="DRAWINGS">FIG. 2A</figref>, the bonding apparatus <b>100</b> includes an arrangement mechanism <b>110</b>, an alignment mechanism <b>120</b>, a pushing mechanism <b>130</b>, a holding mechanism <b>140</b>, a recognition mechanism <b>150</b>, a depressurization mechanism <b>160</b>, and a controller <b>170</b>. In <figref idref="DRAWINGS">FIGS. 2A and 2B</figref>, a direction perpendicular to an upper surface <b>112</b><i>a </i>of a substrate stage <b>112</b> is a Z direction, and two directions orthogonal to each other within a plane parallel to the upper surface <b>112</b><i>a </i>is an X direction and a Y direction.
0049The controller <b>170</b> entirely controls each unit of the bonding apparatus <b>100</b>.
0050The arrangement mechanism <b>110</b> arranges the activated front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> so as to face each other with the back surface <b>11</b><i>b </i>of each semiconductor chip <b>11</b> attached to the front surface <b>1</b><i>a </i>of the adhesive sheet <b>1</b>. For example, the arrangement mechanism <b>110</b> includes a sheet stage <b>111</b> and the substrate stage <b>112</b>.
0051The sheet stage <b>111</b> has a substantially ring shape when seen from the Z direction in correspondence with the flat ring <b>2</b>. The flat ring <b>2</b> is mounted on an upper surface <b>111</b><i>a </i>of the sheet stage <b>111</b> with the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> facing the lower side. The sheet stage <b>111</b> may suction and hold the flat ring <b>2</b> by vacuum adsorption or electrostatic adsorption.
0052The substrate stage <b>112</b> has a planar shape including the substrate <b>20</b> on the inner side when seen from the Z direction in correspondence with the substrate <b>20</b>. The substrate <b>20</b> is mounted on the upper surface <b>112</b><i>a </i>of the substrate stage <b>112</b> with the front surface <b>20</b><i>a </i>facing the upper side. The substrate stage <b>112</b> may suction and hold the substrate <b>20</b> by vacuum adsorption or electrostatic adsorption.
0053The alignment mechanism <b>120</b> aligns the relative positions of the semiconductor chip <b>11</b> and the substrate <b>20</b> under the control by the controller <b>170</b>. For example, the alignment mechanism <b>120</b> includes drive mechanisms <b>121</b>, <b>122</b>. The drive mechanism <b>121</b> drives the sheet stage <b>111</b> in the X direction, the Y direction, and a θ direction in accordance with a command of a drive amount received from the controller <b>170</b>. The θ direction is a rotating direction about the Z axis. The drive mechanism <b>122</b> drives the substrate stage <b>112</b> in the X direction, the Y direction, and the θ direction in accordance with the command of the drive amount received from the controller <b>170</b>.
0054It should be noted that, the alignment mechanism <b>120</b> may have a configuration in which one of the drive mechanism <b>121</b> or the drive mechanism <b>122</b> is omitted as long as the relative positions of the semiconductor chip <b>11</b> and the substrate <b>20</b> can be aligned.
0055The depressurization mechanism <b>160</b> includes a vacuum pump <b>161</b> and vacuum exhaust paths <b>162</b>, <b>163</b>-<b>1</b>, <b>163</b>-<b>2</b>.
0056The pushing mechanism <b>130</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b> to closely attach the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> under the control by the controller <b>170</b> (see <figref idref="DRAWINGS">FIG. 5A</figref>). The semiconductor chip <b>11</b> is thereby temporarily bonded to the substrate <b>20</b>. The pushing mechanism <b>130</b> also strips the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> while maintaining the state in which the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> is closely attached to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> (see <figref idref="DRAWINGS">FIGS. 5B and 5C</figref>). For example, the pushing mechanism <b>130</b> includes a pushing head <b>131</b>, a head drive unit <b>132</b>, a pin <b>135</b>, and a pin drive unit <b>136</b>.
0057The pushing head <b>131</b> has a pushing surface <b>131</b><i>f </i>corresponding to the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>. The pushing surface <b>131</b><i>f </i>has a planar shape that does not interfere with the adjacent semiconductor chip <b>11</b> including the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> to be pushed when seen from the Z direction. The pushing surface <b>131</b><i>f </i>may, for example, have a planar shape that is even with the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>. The head drive unit <b>132</b> drives the pushing head <b>131</b> in the Z direction under the control by the controller <b>170</b>. The pushing head <b>131</b> thus can push the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>.
0058The pushing head <b>131</b> has a buffer member <b>131</b><i>a </i>on the pushing surface <b>131</b><i>f</i>. The buffer member <b>131</b><i>a </i>buffers a force exerted on the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> when the pushing head <b>131</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>, and at the same time, enables a uniform pressure to be exerted on the activated surface by absorbing the shift in planarity of the chip surface and the substrate surface. The buffer member <b>131</b><i>a </i>can be formed, for example, with an elastic body such as a rubber, and the like.
0059The pushing head <b>131</b> has an suctioning structure <b>131</b><i>b </i>for suctioning the adhesive sheet <b>1</b> when the pushing head <b>131</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>. As illustrated in <figref idref="DRAWINGS">FIG. 2B</figref>, the suctioning structure <b>131</b><i>b </i>is formed from a gap of a hole <b>134</b> and the pin <b>135</b>, and a communication path <b>137</b>. The gap of the hole <b>134</b> and the pin <b>135</b> is communicated to the vacuum exhaust path <b>162</b> through the communication path <b>137</b>, and can be vacuum exhausted by the vacuum pump <b>161</b> through the vacuum exhaust path <b>162</b>. Thus, the suctioning structure <b>131</b><i>b </i>can vacuum-suction the adhesive sheet <b>1</b>. The suctioning structure <b>131</b><i>b </i>may be in other modes as long as the adhesive sheet <b>1</b> can be suctioned to the pushing surface <b>131</b><i>f </i>of the pushing head <b>131</b>. For example, the suctioning structure <b>131</b><i>b </i>may be formed by a hole communicated from the pushing surface <b>131</b><i>f </i>to the communication path <b>137</b> separate from the hole, to which the pin <b>135</b> is inserted, and the communication path <b>137</b>.
0060The pin <b>135</b> can be changed between a state of being retracted toward the pushing head <b>131</b> side than the pushing surface <b>131</b><i>f </i>and a state of being projected out from the pushing surface <b>131</b><i>f</i>. The pin <b>135</b> is movable in the Z direction within the hole <b>134</b>. The hole <b>134</b> is extended in the Z direction in the pushing head <b>131</b>. The pin drive unit <b>136</b> moves the pin <b>135</b> in the Z direction along the hole <b>134</b> under the control by the controller <b>170</b>. The pin <b>135</b> is thereby retracted toward the pushing head side <b>131</b> than the pushing surface <b>131</b><i>f </i>or projected out from the pushing surface <b>131</b><i>f. </i>
0061The holding mechanism <b>140</b> is arranged at a periphery of the pushing mechanism <b>130</b>. The holding mechanism <b>140</b> holds the region at the periphery of the region to be pushed with the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b>. The holding mechanism <b>140</b> vacuum-suctions the region at the periphery of the region to be pushed with the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b>. For example, the holding mechanism <b>140</b> includes a plurality of sets of configurations for holding. The plurality of sets of configuration are arranged at positions rotation symmetric with each other with respect to the pushing mechanism <b>130</b> when seen from the Z direction. Each of the plurality of sets of configurations includes holding heads <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b>, and head drive units <b>142</b>-<b>1</b>, <b>142</b>-<b>2</b>.
0062The head drive units <b>142</b>-<b>1</b>, <b>142</b>-<b>2</b> drive the holding heads <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> in the Z direction under the control by the controller <b>170</b>. The holding heads <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> thus can vacuum-suction the adhesive sheet <b>1</b>.
0063Each holding head <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> includes a buffer member <b>141</b><i>a</i>-<b>1</b>, <b>141</b><i>a</i>-<b>2</b> at the surface <b>141</b><i>f </i>that makes contact with the adhesive sheet <b>1</b>. The buffer members <b>141</b><i>a</i>-<b>1</b>, <b>141</b><i>a</i>-<b>2</b> buffer the force exerted on the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> when each holding head <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> vacuum-suctions the adhesive sheet <b>1</b>. The buffer members <b>141</b><i>a</i>-<b>1</b>, <b>141</b><i>a</i>-<b>2</b> can be formed with an elastic body such as rubber, for example.
0064Each holding head <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> includes a suctioning structure <b>141</b><i>b</i>-<b>1</b>, <b>141</b><i>b</i>-<b>2</b> for suctioning the adhesive sheet <b>1</b>. The suctioning structure <b>141</b><i>b</i>-<b>1</b>, <b>141</b><i>b</i>-<b>2</b> is formed by a hole <b>144</b>-<b>1</b>, <b>144</b>-<b>2</b> and a communication path <b>147</b>-<b>1</b>, <b>147</b>-<b>2</b>. The hole <b>144</b>-<b>1</b>, <b>144</b>-<b>2</b> is communicated to the vacuum exhaust path <b>163</b>-<b>1</b>, <b>163</b>-<b>2</b> by way of the communication path <b>147</b>-<b>1</b>, <b>147</b>-<b>2</b>, and can be vacuum exhausted by the vacuum pump <b>161</b> through the vacuum exhaust path <b>163</b>-<b>1</b>, <b>163</b>-<b>2</b>. The suctioning structures <b>141</b><i>b</i>-<b>1</b>, <b>141</b><i>b</i>-<b>2</b> thus can vacuum-suction the adhesive sheet <b>1</b>.
0065The recognition mechanism <b>150</b> recognizes the semiconductor chip <b>11</b> and the substrate <b>20</b>. For example, the recognition mechanism <b>150</b> recognizes each of the position of the semiconductor chip <b>11</b> and the position on the substrate <b>20</b> where the semiconductor chip <b>11</b> is to be mounted. The recognition mechanism <b>150</b> includes, for example, a lens barrel <b>151</b>, a camera <b>152</b>, and a ring illumination <b>153</b>. The recognition mechanism <b>150</b> illuminates an object (e.g., semiconductor chip <b>11</b> and substrate <b>20</b>) with the ring illumination <b>153</b>, and receives the reflected light with the camera <b>152</b> through the lens barrel <b>151</b>. The recognition mechanism <b>150</b> thus can image the semiconductor chip <b>11</b> and the substrate <b>20</b>, and provide the image obtained by imaging to the controller <b>170</b>.
0066For example, the recognition mechanism <b>150</b> can recognize the respective positions of the semiconductor chip <b>11</b> and the substrate <b>20</b> by recognizing the respective contours of the semiconductor chip <b>11</b> and the substrate <b>20</b>. Alternatively, for example, if an alignment mark is formed on each of the semiconductor chip <b>11</b> and the substrate <b>20</b>, the recognition mechanism <b>150</b> can recognize the respective positions of the semiconductor chip <b>11</b> and the substrate <b>20</b> by recognizing the respective alignment marks of the semiconductor chip <b>11</b> and the substrate <b>20</b>.
0067It should be noted that, the recognition mechanism <b>150</b> may include a coaxial illumination in place of the ring illumination <b>153</b>. The coaxial illumination is, for example, arranged in the lens barrel <b>151</b> such that the optical axis is coaxial with the optical axis of the camera <b>152</b>. Alternatively, the recognition mechanism <b>150</b> may include an illumination arranged on a lower side (e.g., upper surface <b>112</b><i>a </i>of the substrate <b>112</b>) in place of the ring illumination <b>153</b>. For example, if the substrate <b>20</b> is the glass substrate, the illumination may be arranged in a region where the substrate <b>20</b> is to be mounted in the upper surface <b>112</b><i>a </i>of the substrate stage <b>112</b>. If the substrate <b>20</b> is the semiconductor substrate, for example, the illumination may be arranged at the periphery of the region where the substrate <b>20</b> is to be mounted in the upper surface <b>112</b><i>a </i>of the substrate stage <b>112</b>.
0068Alternatively, the recognition mechanism <b>150</b> may include an IR illumination <b>154</b> illustrated with a chain dashed line in <figref idref="DRAWINGS">FIG. 2A</figref> in place of the ring illumination <b>153</b>. In this case, the camera <b>152</b> may be an IR camera. Thus, the recognition mechanism <b>150</b> can illuminate a subject (e.g., semiconductor chip <b>11</b> and substrate <b>20</b>) with an IR light (infrared light) exit from the IR illumination <b>154</b>, and receive a transmissive light (IR light) thereof with the camera <b>152</b> through the lens barrel <b>151</b>.
0069Alternatively, although not illustrated, the recognition mechanism <b>150</b> may include an upper and lower simultaneous recognition camera in place of the camera <b>152</b>. The upper and lower simultaneous recognition camera is inserted to a space between the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> and the substrate <b>20</b> to be able to simultaneously image the semiconductor chip <b>11</b> and the substrate <b>20</b>. Thus, the recognition mechanism <b>150</b> can simultaneously recognize the respective positions of the semiconductor chip <b>11</b> and the substrate <b>20</b>.
0070In the bonding method of the semiconductor chip, steps illustrated in <figref idref="DRAWINGS">FIGS. 3A to 3C</figref>, <figref idref="DRAWINGS">FIGS. 4A to 4C</figref>, and <figref idref="DRAWINGS">FIGS. 5A to 5C</figref> are carried out as the temporary bonding in the plasma activated bonding.
0071In the step illustrated in <figref idref="DRAWINGS">FIG. 3A</figref>, the arrangement mechanism <b>110</b> arranges the activated front surfaces <b>11</b><i>a </i>of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> so as to face each other. The back surfaces <b>11</b><i>b </i>of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> are attached to the front surface <b>1</b><i>a </i>of the adhesive sheet <b>1</b>.
0072At this time, the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> are respectively terminated with the hydroxyl group, but the water molecule (H—O—H) is often bonded to the hydroxyl group (—O—H) through hydrogen bonding, as illustrated in <figref idref="DRAWINGS">FIG. 6A</figref>. <figref idref="DRAWINGS">FIGS. 6A to 6D</figref> are views illustrating a mechanism of the plasma activated bonding. In <figref idref="DRAWINGS">FIGS. 6A to 6D</figref>, a case in which the vicinity of the front surface <b>11</b><i>a </i>is a silicon dioxide film <b>11</b><i>i </i>in the semiconductor chip <b>11</b> and a silicon region <b>11</b><i>j </i>is arranged at a position deeper than the silicon dioxide film <b>11</b><i>i</i>, and the vicinity of the front surface <b>20</b><i>a </i>is a silicon dioxide film <b>21</b> in the substrate <b>20</b> and a silicon region <b>22</b> is arranged at a position deeper than the silicon dioxide film <b>21</b> is illustrated.
0073As illustrated in <figref idref="DRAWINGS">FIG. 3A</figref>, the recognition mechanism <b>150</b> recognizes the position in the substrate <b>20</b> where the semiconductor chip <b>11</b> is to be mounted. For example, the recognition mechanism <b>150</b> illuminates the substrate <b>20</b> with the ring illumination <b>153</b>, and receives the reflected light with the camera <b>152</b> through the lens barrel <b>151</b>. Thus, the recognition mechanism <b>150</b> can image the substrate <b>20</b>, and recognize the position indicated with a broken line in <figref idref="DRAWINGS">FIG. 3A</figref> as the position in the substrate <b>20</b> where the semiconductor chip <b>11</b>-<b>4</b> is to be mounted. The recognition mechanism <b>150</b> provides the recognition result to the controller <b>170</b>.
0074In the step illustrated in <figref idref="DRAWINGS">FIG. 3B</figref>, the holding mechanism <b>140</b> holds the region at the periphery of the region to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b>. For example, the controller <b>170</b> can cause the suctioning structures <b>141</b><i>b</i>-<b>1</b>, <b>141</b><i>b</i>-<b>2</b> to be in a vacuum-suctionable state, and controls the head drive units <b>142</b>-<b>1</b>, <b>142</b>-<b>2</b> to move the holding heads <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> in the −Z direction (see <figref idref="DRAWINGS">FIG. 2A</figref>). If the semiconductor chip <b>11</b>-<b>4</b> is selected as the semiconductor chip to be pushed among the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b>, the region at the periphery of the region corresponding to the semiconductor chip <b>11</b>-<b>4</b> in the adhesive sheet <b>1</b> is vacuum-suctioned by the holding mechanism <b>140</b>. In <figref idref="DRAWINGS">FIG. 3B</figref>, a case of vacuum-suctioning the regions corresponding to the semiconductor chips <b>11</b>-<b>2</b>, <b>11</b>-<b>3</b>, <b>11</b>-<b>5</b>, <b>11</b>-<b>6</b> in the adhesive sheet <b>1</b> with the holding heads <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b> is illustrated, but the region is not limited to the regions corresponding to the semiconductor chips <b>11</b>-<b>2</b>, <b>11</b>-<b>3</b>, <b>11</b>-<b>5</b>, <b>11</b>-<b>6</b> as long as it is at the periphery of the region corresponding to the semiconductor chip <b>11</b>-<b>4</b>. Thus, the deflection of the region to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b> can be controlled.
0075In the step illustrated in <figref idref="DRAWINGS">FIG. 3C</figref>, the recognition mechanism <b>150</b> recognizes the position to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b>. For example, the recognition mechanism <b>150</b> illuminates the adhesive sheet <b>1</b> and the semiconductor chip <b>11</b>-<b>4</b> with the ring illumination <b>153</b>, and receives the reflected light with the camera <b>152</b> through the lens barrel <b>151</b>. Thus, the recognition mechanism <b>150</b> can image the adhesive sheet <b>1</b> and the semiconductor chip <b>11</b>-<b>4</b>, and recognize the position indicated with a broken line in <figref idref="DRAWINGS">FIG. 3C</figref> as the position to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b>. The recognition mechanism <b>150</b> provides the recognition result to the controller <b>170</b>.
0076It should be noted that, the position (absolute position or the relative position with respect to the substrate <b>20</b>) of the adhesive sheet <b>1</b> and the semiconductor chop <b>11</b>-<b>4</b> has a possibility of shifting when the holding mechanism <b>140</b> vacuum-suctions the adhesive sheet <b>1</b> in the step illustrated in <figref idref="DRAWINGS">FIG. 3B</figref>, but the recognized position is less likely to be subjected to the influence of shift since the position of after the shift can be recognized in the step illustrated in <figref idref="DRAWINGS">FIG. 3C</figref>.
0077In the step illustrated in <figref idref="DRAWINGS">FIG. 4A</figref>, the pushing mechanism <b>130</b> vacuum-suctions the adhesive sheet <b>1</b>. For example, the controller <b>170</b> obtains the drive amount of the sheet stage <b>111</b> for positioning the position to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b> to under the pushing mechanism <b>130</b> and provides the same to the drive mechanism <b>121</b> of the alignment mechanism <b>120</b> according to the recognition result by the recognition mechanism <b>150</b>. The drive mechanism <b>121</b> drives the sheet stage <b>111</b> according to the command of the drive amount. The position to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b> is thereby positioned under the pushing mechanism <b>130</b>. The controller <b>170</b> causes the suctioning structure <b>131</b><i>b </i>to be in a vacuum-suctioning state, and controls the head drive unit <b>132</b> to move the pushing head <b>131</b> in the −Z direction (see <figref idref="DRAWINGS">FIG. 2A</figref>). Thus, the adhesive sheet <b>1</b> is vacuum-suctioned to the pushing surface <b>131</b><i>f </i>of the pushing head <b>131</b>. In this case, the pin <b>135</b> is maintained in a state retracted toward the pushing head <b>131</b> side from the pushing surface <b>131</b><i>f. </i>
0078In the step illustrated in <figref idref="DRAWINGS">FIG. 4B</figref>, the recognition mechanism <b>150</b> recognizes the position (absolute position or relative position with respect to the substrate <b>20</b>) of the semiconductor chip <b>11</b>. For example, the recognition mechanism <b>150</b> illuminates the semiconductor chip <b>11</b>-<b>4</b> with the ring illumination <b>153</b>, and receives the reflected light with the camera <b>152</b> through the lens barrel <b>151</b>. The recognition mechanism <b>150</b> can image the semiconductor chip <b>11</b>-<b>4</b>, and recognize the position of the semiconductor chip <b>11</b>. The recognition mechanism <b>150</b> provides the recognition result to the controller <b>170</b>.
0079It should be noted that, although the position (absolute position or the relative position with respect to the substrate <b>20</b>) of the adhesive sheet <b>1</b> and the semiconductor chop <b>11</b>-<b>4</b> has a possibility of shifting when the pushing mechanism <b>130</b> vacuum-suctions the adhesive sheet <b>1</b> in the step illustrated in <figref idref="DRAWINGS">FIG. 4A</figref>, the position to be recognized is less likely to be subjected to the influence of shift since the position of after the shift can be recognized in the step illustrated in <figref idref="DRAWINGS">FIG. 4B</figref>.
0080In the step illustrated in <figref idref="DRAWINGS">FIG. 4C</figref>, the alignment mechanism <b>120</b> aligns the relative positions of the semiconductor chip <b>11</b> and the substrate <b>20</b>. For example, the controller <b>170</b> obtains the drive amount for alignment based on the recognition result received in the step illustrated in <figref idref="DRAWINGS">FIG. 3A</figref> and the recognition result received in the step illustrated in <figref idref="DRAWINGS">FIG. 4B</figref>. For example, the controller <b>170</b> obtains a difference ΔL (see <figref idref="DRAWINGS">FIG. 4B</figref>) of the position in the substrate <b>20</b> where the semiconductor chip <b>11</b>-<b>4</b> is to be mounted and the position of the semiconductor chip <b>11</b>-<b>4</b> for each of the X direction, the Y direction, and the θ direction. The controller <b>170</b> obtains the drive amount of each of the X direction, the Y direction, and the θ direction so as to cancel the difference ΔL, and provides the same to the drive mechanism <b>122</b> of the alignment mechanism <b>120</b>. The drive mechanism <b>122</b> drives the substrate stage <b>112</b> according to the command of the drive amount. Thus, the position of the semiconductor chip <b>11</b>-<b>4</b> and the position in the substrate <b>20</b> where the semiconductor chip <b>11</b>-<b>4</b> is to be mounted are relatively aligned.
0081In the step illustrated in <figref idref="DRAWINGS">FIG. 5A</figref>, the pushing mechanism <b>130</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>11</b>. For example, the controller <b>170</b> controls the head drive unit <b>132</b> to move the pushing head <b>131</b> further in the −Z direction (see <figref idref="DRAWINGS">FIG. 2A</figref>). Thus, the pushing head <b>131</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>-<b>4</b> through the adhesive sheet <b>1</b>, and closely attaches the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b>-<b>4</b> to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b>. The semiconductor chip <b>11</b>-<b>4</b> is thereby temporarily bonded to the substrate <b>20</b>. The adhesive sheet <b>1</b> is also elastically deformed thus generating a tensile force between the region pushed with the pushing mechanism <b>130</b> and the region held with the holding mechanism <b>140</b> (holding heads <b>141</b>-<b>1</b>, <b>141</b>-<b>2</b>).
0082At this time, as illustrated in <figref idref="DRAWINGS">FIG. 6B</figref>, the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> are temporarily bonded as the water molecules (H—O—H) bonded to the hydroxyl group are bonded to each other by hydrogen bonding.
0083In the step illustrated in <figref idref="DRAWINGS">FIG. 5B</figref>, the pushing mechanism <b>130</b> strips the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> while maintaining the state in which the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> is closely attached to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b>. For example, the controller <b>170</b> controls the pin drive unit <b>136</b> to enable the pin <b>135</b> to push the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>. The controller <b>170</b> controls the depressurization mechanism <b>160</b> to release the vacuum adsorption of the suctioning structure <b>131</b><i>b</i>. The controller <b>170</b> controls the head drive unit <b>132</b> to move the pushing head <b>131</b> in the +Z direction while controlling the pin drive unit <b>136</b> to maintain the state in which the pin <b>135</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b> (see <figref idref="DRAWINGS">FIG. 2A</figref>). In other words, as the pushing head <b>131</b> moves in the +Z direction away from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>, the pin <b>135</b> projects out from the pushing surface <b>131</b><i>f </i>while maintaining the state of pushing the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>.
0084At this time, the adhesion force of the adhesive formed on the front surface <b>1</b><i>a </i>of the adhesive sheet <b>1</b> is lowered in the step illustrated in <figref idref="DRAWINGS">FIG. 1B</figref>. Thus, the adhesive sheet <b>1</b> is easily stripped from the periphery of the region pushed with the pin <b>135</b> in the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>-<b>4</b> by the tensile force between the region pushed with the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b> and the region held by the holding mechanism <b>140</b>.
0085In the step illustrated in <figref idref="DRAWINGS">FIG. 5C</figref>, the pushing mechanism <b>130</b> completes the stripping of the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>. For example, the controller <b>170</b> controls the pin drive unit <b>136</b> to move the pin <b>135</b> in the +Z direction, and releases the state of pushing the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>. The controller <b>170</b> may control the pin drive unit <b>136</b> to have the pin <b>135</b> in the state retracted toward the pushing head <b>131</b> side than the pushing surface <b>131</b><i>f. </i>
0086Consider a case of releasing the pushing by the pushing head <b>131</b> to release, all at once, the pushing against the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> without having the pin <b>135</b> push the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>. In this case, substantially the entire surface of the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>-<b>4</b> is adhered to the adhesive sheet <b>1</b>, and the area of the region adhered to the adhesive sheet <b>1</b> in the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>-<b>4</b> is large. Thus, the force of pulling the semiconductor chip <b>11</b>-<b>4</b> upward with the tensile force and the adhesive force of the adhesive sheet <b>1</b> may become greater than the force of pulling the semiconductor chip <b>11</b>-<b>4</b> downward with the force of the temporary bonding of the semiconductor chip <b>11</b>-<b>4</b> to the substrate <b>20</b>. Thus, the state in which the semiconductor chip <b>11</b>-<b>4</b> is temporarily bonded to the substrate <b>20</b> may not be maintained and the semiconductor chip <b>11</b>-<b>4</b> may be stripped from the substrate <b>20</b>.
0087On the contrary, in the present embodiment, the area of the region adhered to the adhesive sheet <b>1</b> in the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>-<b>4</b> is small in the step illustrated in <figref idref="DRAWINGS">FIG. 5C</figref>. Thus, the force of pulling the semiconductor chip <b>11</b>-<b>4</b> downward with the force of the temporarily bonding of the semiconductor chip <b>11</b>-<b>4</b> to the substrate <b>20</b> can easily overcome the force of pulling the semiconductor chip <b>11</b>-<b>4</b> upward with the tensile force and the adhesive force of the adhesive sheet <b>1</b>. The stripping of the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> thus can be completed while maintaining the state in which the semiconductor chip <b>11</b>-<b>4</b> is temporarily bonded to the substrate <b>20</b>.
0088Similarly, other semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>3</b>, <b>11</b>-<b>5</b>, <b>11</b>-<b>6</b> attached to the adhesive sheet <b>1</b> can be temporarily bonded to the substrate <b>20</b> by carrying out the steps of <figref idref="DRAWINGS">FIGS. 3A to 3C</figref>, <figref idref="DRAWINGS">FIGS. 4A to 4C</figref>, and <figref idref="DRAWINGS">FIGS. 5A to 5C</figref>.
0089In the bonding method of the semiconductor chip, the step illustrated in <figref idref="DRAWINGS">FIG. 5D</figref> is then carried out as the actual bonding in the plasma activated bonding.
0090In the step illustrated in <figref idref="DRAWINGS">FIG. 5D</figref>, the semiconductor chip <b>11</b> is heated with the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> physically pressurized. For example, the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> is thermally brought into contact with the hot plate through a buffer sheet (made from a heat resisting material), and heated at lower than or equal to 250° C., for example. At the same time, the substrate <b>20</b> may be brought into contact with a different hot plate from the back surface <b>20</b><i>b </i>side and heated at lower than or equal to 250° C. The heating temperature is desirably appropriately (e.g., suitably) set according to the material and the structure of the semiconductor chip and the substrate, and for example, can be higher than or equal to 1000° C. if between materials having the same coefficient of thermal expansion, for example, so that the time for the bonding process to be described later can be reduced and the productivity can be enhanced. In the bonding between materials having different coefficients of thermal expansion such as the silicon and the III-V group semiconductor, the residual heat stress due to the lowering of the temperature after the bonding process is terminated reduces, and hence the temperature is recommended to be as low as possible, and desirably, lower than or equal to 150° C.
0091In the process of pressurization and heating described above, at the bonding interface of the semiconductor chip <b>11</b> and the substrate <b>20</b>, the water molecules (H—O—H) pass from the bonding interface, and the hydrogen bonding of the water molecules (H—O—H) change to the hydrogen bonding of the hydroxyl groups (—O—H) or change to the covalent bonding through an oxygen atom (—O—), as illustrated in <figref idref="DRAWINGS">FIG. 6C</figref>. The bonding interface width of the front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> and the front surface <b>20</b><i>a </i>of the substrate <b>20</b> is thus narrowed from G<b>1</b> to G<b>2</b> (<G<b>1</b>). As the bonding process advances, at the bonding interface of the semiconductor chip <b>11</b> and the substrate <b>20</b>, the water molecules (H—O—H) pass from the hydrogen bonding of the hydroxyl groups (—O—H) thus changing to the covalent bonding through the oxygen atom (—O—), as illustrated in <figref idref="DRAWINGS">FIG. 6D</figref>. The bonding interface width of the front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> and the front surface <b>20</b><i>a </i>of the substrate <b>20</b> is thus narrowed from G<b>2</b> to G<b>3</b> (<<G<b>2</b>), and the oxide films <b>11</b><i>i</i>, <b>21</b> of the front surfaces are actually bonded in a substantially integrated manner.
0092It should be noted that the actual bonding can be performed without physical pressure depending on the material of the substrate and the material of the semiconductor chip. In this case, in the step illustrated in <figref idref="DRAWINGS">FIG. 5D</figref>, the semiconductor chip <b>11</b> can be heated without physically pressuring the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b>. For example, if the semiconductor chip is formed of In—P material system, the actual bonding can be performed with heating at about 200° C. without physical pressure. In this way, whether or not physical pressure is necessary in the actual bonding steps changes depending on various conditions such as materials or chip sizes.
0093As described above, in the embodiment, the front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> and the front surface <b>20</b><i>a </i>of the substrate <b>20</b> are respectively activated by plasma thus closely attaching the semiconductor chip <b>11</b> to the substrate <b>20</b> in the boding method of the semiconductor chip. Thus, the semiconductor chip <b>11</b> can be temporarily bonded on the substrate <b>20</b> at a normal temperature without interposing the solder bump, whereby the semiconductor chip <b>11</b> can be mounted on the substrate <b>20</b> while suppressing the thermal deformation of the semiconductor chip <b>11</b>. As a result, the alignment accuracy of the bonding of the semiconductor chip at the time of temporary bonding can be easily enhanced. Although the semiconductor chip <b>11</b> is subsequently heated and pressurized to be actually bonded to the substrate <b>20</b>, the alignment accuracy of the bonding of the semiconductor chip in the actual bonding can be easily enhanced since the bonding position of the semiconductor chip <b>11</b> on the substrate <b>20</b> can be substantially fixed with the temporary bonding.
0094In the embodiment, the semiconductor chip <b>11</b> can be bonded onto the substrate <b>20</b> without interposing the solder bump in the bonding method of the semiconductor chip, and hence the arrangement density of the pad electrodes in the semiconductor chip <b>11</b> can be easily enhanced. For example, the arrangement pitch of the pad electrodes in the semiconductor chip may be about a few μm. The mounting density of the semiconductor chip <b>11</b> thus can be easily enhanced.
0095Furthermore, in the embodiment, the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> attached to the adhesive sheet <b>1</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> are arranged to face each other, and the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> is pushed through the adhesive sheet <b>1</b> to temporarily bond the semiconductor chip <b>11</b> to the substrate <b>20</b> in the bonding method of the semiconductor chip. The adhesive sheet <b>1</b> is stripped from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> while maintaining the state in which the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> is closely attached to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b>. Thus, the semiconductor chip <b>11</b> can be handled without touching the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> when temporarily bonding the semiconductor chip <b>11</b> to the substrate <b>20</b>, and the temporary bonding can be completed while suppressing the production of particles.
0096In the embodiment, the activated front surfaces <b>11</b><i>a </i>of the plurality of semiconductor chips <b>11</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> are arranged to face each other with the back surfaces <b>11</b><i>b </i>of the plurality of semiconductor chips <b>11</b> attached to the adhesive sheet <b>1</b> in the bonding method of the semiconductor chip. The process of pushing the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> selected from the plurality of semiconductor chips <b>11</b> to closely attach the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b>, and stripping the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> while maintaining the closely attached state is sequentially carried out for each semiconductor chip <b>11</b>. Thus, the temporary bonding of the plurality of semiconductor chips <b>11</b> to the substrate <b>20</b> can be efficiently carried out while suppressing the production of particles.
0097Moreover, in the embodiment, the interval of the plurality of semiconductor chips <b>11</b> on the adhesive sheet <b>1</b> is widened before arranging the activated front surfaces <b>11</b><i>a </i>of the plurality of semiconductor chips <b>11</b> and the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> so as to face each other in the bonding method of the semiconductor chip. For example, the interval of the plurality of semiconductor chips <b>11</b> on the adhesive sheet <b>1</b> is made wider than the thickness of the semiconductor chip <b>11</b>. Thus, the side surface <b>11</b><i>c </i>of the semiconductor chip <b>11</b> to be pushed is less likely to make contact with the side surface <b>11</b><i>c </i>of the adjacent semiconductor chip <b>11</b> and the production of particles can be suppressed in the step of pushing the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>.
0098In the embodiment, the step of pushing the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b> is carried out with the region at the periphery of the region to be pushed in the adhesive sheet <b>1</b> held by the holding mechanism <b>140</b> in the bonding method of the semiconductor chip. Thus, the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> can be pushed through the adhesive sheet <b>1</b> with the deflection of the adhesive sheet <b>1</b> appropriately controlled, so that the stripping of the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> can be subsequently carried appropriately.
0099In the embodiment, the pushing mechanism <b>130</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b> to closely attach the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b> in the bonding apparatus of the semiconductor chip. The pushing mechanism <b>130</b> also strips the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> while maintaining the state in which the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> is closely attached to the activated front surface <b>20</b><i>a </i>of the substrate <b>20</b>. Thus, the semiconductor chip <b>11</b> can be handled without touching the activated front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b> when temporarily bonding the semiconductor chip <b>11</b> to the substrate <b>20</b>, and the temporary bonding can be carried out while suppressing the production of particles.
0100In the embodiment, the pushing head <b>131</b> includes the pushing surface <b>131</b><i>f </i>in correspondence with the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> in the pushing mechanism <b>130</b> of the bonding apparatus of the semiconductor chip. The back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> thus can be pushed at a substantially uniform force within the plane.
0101In the embodiment, the pin <b>135</b> can be changed between the state of being retracted toward the pushing head <b>131</b> side than the pushing surface <b>131</b><i>f </i>and the state of being projected out from the pushing surface <b>131</b><i>f </i>in the pushing mechanism <b>130</b> of the bonding apparatus of the semiconductor chip. Thus, the pin <b>135</b> is retracted toward the pushing head <b>131</b> side than the pushing surface <b>131</b><i>f </i>when the pushing head <b>131</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b>, so that the pin <b>135</b> does not become a hindrance in the pushing operation of the pushing head <b>131</b>. The pin <b>135</b> is projected out from the pushing surface <b>131</b><i>f </i>when the pushing by the pushing head <b>131</b> is released, so that the stripping of the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> can be easily completed while maintaining the state in which the semiconductor chip <b>11</b>-<b>4</b> is temporarily bonded to the substrate <b>20</b>.
0102In the embodiment, the pushing mechanism <b>130</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b> toward the substrate <b>20</b> side with the region at the periphery of the region to be pushed by the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b> held by the holding mechanism <b>140</b> in the bonding apparatus of the semiconductor chip. Thus, the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> can be pushed through the adhesive sheet <b>1</b> with the deflection of the adhesive sheet <b>1</b> appropriately controlled, so that the stripping of the adhesive sheet <b>1</b> from the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> can be subsequently carried appropriately.
0103In the embodiment, the alignment mechanism <b>120</b> positions the region to be pushed with the pushing mechanism <b>130</b> in the adhesive sheet <b>1</b> based on the recognition result of the recognition mechanism <b>150</b> in the bonding apparatus of the semiconductor chip. The alignment mechanism <b>120</b> aligns the relative positions of the semiconductor chip <b>11</b> and the substrate <b>20</b> based on the recognition result of the recognition mechanism <b>150</b>. The pushing mechanism <b>130</b> pushes the back surface <b>11</b><i>b </i>of the semiconductor chip <b>11</b> through the adhesive sheet <b>1</b> with the relative positions of the semiconductor chip <b>11</b> and the substrate <b>20</b> aligned. Thus, the pushing mechanism <b>130</b> can accurately push, and each of the plurality of semiconductor chips <b>11</b> attached to the adhesive sheet <b>1</b> can be mounted on appropriate positions on the substrate <b>20</b>.
0104It should be noted that, in the step illustrated in <figref idref="DRAWINGS">FIG. 1C</figref>, for example, the interval of the adjacent semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> can be widened by decimating the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b>. For example, the interval of the adjacent semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> can be widened to an extent corresponding to one chip width by decimating the semiconductor chips <b>11</b>-<b>2</b>, <b>11</b>-<b>4</b>, <b>11</b>-<b>6</b> from the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b>. However, particles may produce when decimating the semiconductor chips <b>11</b>-<b>2</b>, <b>11</b>-<b>4</b>, <b>11</b>-<b>6</b>. Therefore, after the decimation, the washing (e.g., ultrasonic washing) and the drying processes are sequentially carried out with respect to the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> with each semiconductor chip <b>11</b> attached to the adhesive sheet <b>11</b>. The particles attached to the front surface <b>11</b><i>a </i>of each semiconductor chip <b>11</b> are thereby removed.
0105The timing to carry out the step (step illustrated in <figref idref="DRAWINGS">FIG. 1D</figref>) of widening the interval of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> merely needs to be before the step (step illustrated in <figref idref="DRAWINGS">FIG. 3A</figref>) of arranging the semiconductor chip <b>11</b> and the substrate <b>20</b> to face each other, and is not limited to after the step illustrated in <figref idref="DRAWINGS">FIG. 1B</figref>. For example, the timing to carry out the step (step illustrated in <figref idref="DRAWINGS">FIG. 1D</figref>) of widening the interval of the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> may be after the step illustrated in <figref idref="DRAWINGS">FIG. 1D</figref> and before the step illustrated in <figref idref="DRAWINGS">FIG. 3A</figref>.
0106In the bonding method of the semiconductor chip, the steps illustrated in <figref idref="DRAWINGS">FIGS. 7A to 7D</figref> may be carried out in place of the steps illustrated in <figref idref="DRAWINGS">FIGS. 1A and 1B</figref>.
0107In the step illustrated in <figref idref="DRAWINGS">FIG. 7A</figref>, the semiconductor substrate <b>10</b> similar to that prepared in the step illustrated in <figref idref="DRAWINGS">FIG. 1A</figref> is prepared. The front surface <b>10</b><i>a </i>of the prepared semiconductor substrate <b>10</b> is attached to a front surface <b>3</b><i>a </i>of an adhesive sheet (dicing tape) <b>3</b>. In other words, the semiconductor substrate <b>10</b> is attached to the adhesive sheet <b>3</b> with the back surface <b>10</b><i>b </i>exposed (face-down state). The adhesive sheet <b>3</b> has an adhesive applied on the front surface <b>3</b><i>a</i>. The adhesive may be, for example, an adhesive having UV curability. The adhesive sheet <b>3</b> is stretched within a frame of an annular flat ring <b>4</b> and fixed to the flat ring <b>4</b>. The adhesive sheet <b>3</b> is, for example, made from a transparent resin having light permeability.
0108In the step illustrated in <figref idref="DRAWINGS">FIG. 7B</figref>, the semiconductor substrate <b>10</b> is divided and singulated to a plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b>. For example, the semiconductor substrate <b>10</b> is dicing processed along the dicing line. The dicing process may be carried out by cutting with the dicing blade along the dicing line. Alternatively, the dicing process may be carried out by emitting laser along the dicing line to perform laser processing.
0109Since the semiconductor substrate <b>10</b> is attached to the adhesive sheet <b>3</b> with the back surface <b>10</b><i>b </i>exposed (face-down state), the particles can be prevented from attaching to the front surface <b>11</b><i>a </i>of the semiconductor chip <b>11</b>.
0110Thereafter, the UV irradiation is carried out on the adhesive sheet <b>3</b> from the back surface <b>3</b><i>b </i>side to cure the adhesive applied on the front surface <b>3</b><i>a </i>of the adhesive sheet <b>3</b> thus lowering the adhesion force thereof.
0111The washing (e.g., ultrasonic washing) and the drying processes may be sequentially carried out with respect to the back surface <b>11</b><i>b </i>of each semiconductor chip <b>11</b> with each semiconductor chip <b>11</b> attached to the adhesive sheet <b>3</b>. Thus, if the particles are attached to the back surface <b>11</b><i>b </i>of each semiconductor chip <b>11</b>, the attached particles can be removed.
0112In the step illustrated in <figref idref="DRAWINGS">FIG. 7C</figref>, the front surface <b>1</b><i>a </i>of the adhesive sheet <b>1</b> is attached to the back surfaces <b>11</b><i>b </i>of the plurality of singulated semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b>. In this case, the adhesion force of the adhesive formed on the front surface <b>3</b><i>a </i>of the adhesive <b>3</b> is lowered in the step illustrated in <figref idref="DRAWINGS">FIG. 7B</figref>. Thus, the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> are easily transferred from the adhesive sheet <b>3</b> to the adhesive sheet <b>1</b>. In other words, the semiconductor substrate <b>10</b> is attached to the adhesive sheet <b>1</b> with the front surface <b>10</b><i>a </i>exposed (face-up state).
0113In the step illustrated in <figref idref="DRAWINGS">FIG. 7D</figref>, the adhesive sheet <b>1</b>, to which the plurality of semiconductor chips <b>11</b>-<b>1</b> to <b>11</b>-<b>6</b> are transferred, is stretched within the frame of the annular flat ring <b>2</b> and fixed to the flat ring <b>2</b>.
0114Thereafter, the step illustrated in <figref idref="DRAWINGS">FIG. 1C</figref> and the subsequent steps are carried out.
0115The dicing process of the semiconductor substrate <b>10</b> is carried out with the semiconductor substrate <b>10</b> faced down, so that the attachment of the particles produced at the time of the dicing process to the front surface <b>11</b><i>a </i>of each singulated semiconductor chip <b>11</b> can be further reduced, and the particles can be effectively suppressed from interposing at the bonding interface at the time of the temporary bonding of the semiconductor chip <b>11</b> to the substrate <b>20</b>.
0116While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
0000(Additional Note 1)
0117A bonding method of a semiconductor chip comprising:
0118arranging an activated front surface of a semiconductor chip and an activated front surface of a substrate so as to face each other with a back surface of the semiconductor chip attached to a sheet;
0119pushing the back surface of the semiconductor chip through the sheet to closely attach the activated front surface of the semiconductor chip and the activated front surface of the substrate; and
0120stripping the sheet from the back surface of the semiconductor chip while maintaining the state in which the activated front surface of the semiconductor chip is closely attached to the activated front surface of the substrate.
0000(Additional Note 2)
0121The bonding method of the semiconductor chip according to additional note 1, further comprising
0122irradiating the front surface of the semiconductor chip with a plasma or an energy beam with the back surface of the semiconductor chip attached to the sheet to activate the front surface before the arranging step.
0000(Additional Note 3)
0123The bonding method of the semiconductor chip according to additional note 1, further comprising
0124heating the semiconductor chip with the back surface of the semiconductor chip pressurized after the stripping.
0000(Additional Note 4)
0125The bonding method of the semiconductor chip according to additional note 1, wherein
0126a vicinity of the front surface of the semiconductor chip is made of a material having any one of a silicon, a silicon oxide, a III-V group semiconductor, or an oxide of the III-V group semiconductor as a main component.
0000(Additional Note 5)
0127The bonding method of the semiconductor chip according to additional note 1, wherein
0128the substrate includes a semiconductor substrate or a glass substrate.
0000(Additional Note 6)
0129The bonding method of the semiconductor chip according to additional note 5, wherein
0130a vicinity of the front surface of the semiconductor substrate is made of a material having a silicon or a silicon oxide as a main component.
0000(Additional Note 7)
0131The bonding method of the semiconductor chip according to additional note 1, wherein
0132the front surface of the semiconductor chip has planarity of smaller than or equal to 1 nm.
0000(Additional Note 8)
0133The bonding method of the semiconductor chip according to additional note 1, wherein
0134the front surface of the substrate has planarity of smaller than or equal to 1 nm.
0000(Additional Note 9)
0135The bonding method of the semiconductor chip according to additional note 1, wherein
0136the arranging includes arranging activated front surfaces of a plurality of semiconductor chips and the activated front surface of the substrate so as to face each other with back surfaces of the plurality of semiconductor chips attached to the sheet,
0137the closely attaching includes pushing the back surface of the semiconductor chip selected from the plurality of semiconductor chips through the sheet to closely attach the activated front surface of the selected semiconductor chip and the activated front surface of the substrate, and
0138the stripping includes stripping the sheet from the back surface of the selected semiconductor chip.
0000(Additional Note 10)
0139The bonding method of the semiconductor chip according to additional note 9, further comprising
0140widening an interval of the plurality of semiconductor chips before the arranging.
0000(Additional Note 11)
0141The bonding method of the semiconductor chip according to additional note 10, wherein
0142the widening includes widening the interval of the plurality of semiconductor chips to greater than a thickness of the semiconductor chip.
0000(Additional Note 12)
0143The bonding method of the semiconductor chip according to additional note 9, wherein
0144the closely attaching includes pushing the back surface of the selected semiconductor chip through the sheet while holding a region at a periphery of the selected semiconductor chip in the sheet.
0000(Additional Note 13)
0145The bonding method of the semiconductor chip according to additional note 12, wherein
0146the holding includes suctioning and holding the region at the periphery of the selected semiconductor chip in the sheet.
0000(Additional Note 14)
0147The bonding method of the semiconductor chip according to additional note 9, further comprising:
0148attaching a front surface of a second semiconductor substrate to a second sheet;
0149dividing the second semiconductor substrate to singulate to the plurality of semiconductor chips; and
0150attaching the back surfaces of the singulated plurality of semiconductor chips to the sheet, and transferring the plurality of semiconductor chips from the second sheet to the sheet.
0000(Additional Note 15)
0151A bonding apparatus of a semiconductor chip comprising:
0152an arrangement mechanism configured to arrange an activated front surface of a semiconductor chip and an activated front surface of a substrate so as to face each other with a back surface of the semiconductor chip attached to a sheet; and
0153a pushing mechanism configured to push the back surface of the semiconductor chip through the sheet to closely attach the activated front surface of the semiconductor chip to the activated front surface of the substrate, and strip the sheet from the back surface of the semiconductor chip while maintaining the state in which the activated front surface of the semiconductor chip is closely attached to the activated front surface of the substrate.
0000(Additional Note 16)
0154The bonding apparatus of the semiconductor chip according to additional note 15, wherein
0155the pushing mechanism includes,
0156a pushing head including a pushing surface corresponding to the back surface of the semiconductor chip, and
0157a pin configured to be changed between a state retracted toward the pushing head side than the pushing surface and a state projected out from the pushing surface.
0000(Additional Note 17)
0158The bonding apparatus of the semiconductor chip according to additional note 16, wherein
0159the pushing head includes a buffer member on the pushing surface.
0000(Additional Note 18)
0160The bonding apparatus of the semiconductor chip according to additional note 16, wherein
0161the pushing head has an suctioning structure of suctioning the sheet.
0000(Additional Note 19)
0162The bonding apparatus of the semiconductor chip according to additional note 15, further comprising a holding mechanism arranged at a periphery of the pushing mechanism, wherein
0163the pushing mechanism pushes the back surface of the semiconductor chip through the sheet toward the substrate side with a region at a periphery of the region to be pushed with the pushing mechanism in the sheet held by the holding mechanism.
0000(Additional Note 20)
0164The bonding apparatus of the semiconductor chip according to additional note 15, further comprising:
0165a recognition mechanism configured to recognize the substrate and the semiconductor chip; and
0166an alignment mechanism configured to align relative positions of the semiconductor chip and the substrate based on a recognition result of the recognition mechanism, wherein
0167the pushing mechanism pushes the back surface of the semiconductor chip through the sheet with the relative positions of the semiconductor chip and the substrate aligned.
Contents5
9 sheets
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8 Sheet 9
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8 members in 2 offices; this record represents the family
Priority claims2
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| 2014221907 | Japan | A |
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63 transactions on the USPTO file
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Numbers
- Publication
- 9728519
- Application
- 14710070
Titles
- English
- Bonding method of semiconductor chip and bonding apparatus of semiconductor chip
Patent term adjustment
- Applicant delay
- −49 days
- Net adjustment
- 0 days
Classification
- CPC, 27
- H01L24/97
- H10P72/0442
- H10P70/30
- H01L21/67132
- H01L24/75
- H10W72/0198
- H01L24/83
- H10W72/073
- H01L21/02076
- H01L2224/753
- H10W72/07141
- H01L2224/756
- H10W72/07163
- H01L2224/759
- H10W72/07168
- H01L2224/7525
- H10W72/07178
- H01L2224/7555
- H10W72/07183
- H01L2224/75743
- H10W72/07331
- H01L2224/832
- H01L2224/838
- H01L2224/83104
- H01L2924/05442
- H01L2924/1032
- H01L2924/10253
- IPC, 4
- H01L23 00
- H01L21 67
- H01L21 02
- H10P72 00